Ridge tile or solar panel attachment system for a roof

ABSTRACT

An improved solar panel attachment system for a roof and method for its use include a pedestal that has a plurality of protrusions and keyways located along its bottom wall surface and extending along the length of the pedestal. The pedestal is placed into a paddy of foam adhesive laid along a roof underlayment and the keyways receive and engage with the expanding adhesive for bonding the pedestal directly to the roof without the need for mechanical fastening. The protrusions provide spacing between the bottom wall surface and the roof so that an adequate amount of foam adhesive resides between these wall surfaces and those structures. Attaching means are secured to the top wall surface so that the pedestal may be used to securely mount (or secure) a solar panel or other object to a roof.

CROSS-REFERENCE TO CO-PENDING APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/643,086 and claims the benefit of that application.

BACKGROUND OF THE INVENTION

This invention relates generally to hip and ridge attachment systems forroofing materials and, more particularly, to attachment systems for capor trim roof tiles, field tiles, and other roof products such as solarcomponents in high wind environments.

In August 1992, one of the most devastating hurricanes in U.S. history,category 5 Hurricane Andrew, made landfall. The aftermath wasdevastating. Andrew caused more than $40 billion in property damage and90% of Dade County, Florida homes suffered major roof damage. At thattime, the common and approved building practice for tiled roofs was toset a trim, cap or ridge tile with cement mortar and secure it to afield tile, thereby making the field tile the primary point of contactto the roof for the ridge tile.

To ensure that this extensive amount of wind damage would never happenagain, Dade County created new building codes. In regards to attachmentsystems for ridge roof tiles, the solution was to anchor wood orgalvanized steel to the roof and then use an adhesive to better securethe ridge tiles to the wood or steel. Unlike the prior system, theprimary point of contact for the ridge tile became the wood or steelthat was secured to the roof rather than the field tile. In regards tosolar panels, wood or galvanized steel is attached to the roof and thenused to support and anchor the panels to the roof.

However, the problem with both wood and galvanized steel systems is thatin order to properly anchor the system to the roof it must be nailed tothe roof, using two nails every six inches. This amount of nailingcauses a lot of penetration through the roof underlayment and decking,thereby providing a leak pathway through the underlayment and decking.Furthermore, wood is heavy, it warps, and it rots over time. Galvanizedsteel is easily dented, has sharp edges, and is known to rust.Therefore, a need exists for an attachment system for ridge roof tilesor solar panels in high wind environments that provides a better primarycontact to the roof, is lightweight, eliminates penetration and is easyto install, resists rot and corrosion, and provides superior performancein comparison to existing wood and galvanized steel systems.

SUMMARY OF THE INVENTION

An improved roof ridge apparatus made according to this inventionincludes a longitudinally extending rigid member with an optionalcentral passageway and a plurality of protrusions extending away from aportion of its top and bottom wall surfaces. The protrusions providespacing between the bottom wall surface and a roof and between the topwall surface and a roof tile so that an adequate amount of foam adhesiveresides between these wall surfaces and those structures. Theprotrusions have keyways at their upper end that provide additionalsurface area for bonding to the adhesive. As the foam adhesive expandsit surrounds the protrusions and enters into the keyways. Once theadhesive cures, the rigid member is securely affixed to the roof withoutthe need for mechanical fasteners and the roof tile is securely affixedto the rigid member. Preferably, the rigid member is an extrudedolefin-based polymer member.

A method for installing the roof ridge apparatus to a roof includes thesteps of applying a foam adhesive to a roof underlayment and positioningthe longitudinally extending rigid member onto the foam adhesive. Foamadhesive is applied to the top surface of the positioned rigid memberand a trim tile is positioned over the top surface. Prior to installingthe trim tile, weather block may be applied to the field tile locatedalongside the positioned rigid member.

An improved apparatus and system for mounting a solar panel above a roofincludes a pedestal with a plurality of protrusions that extend alongand away from the bottom wall surface of the pedestal. At least oneprotrusion defines at least one keyway within that protrusion that canreceive an adhesive for securing the pedestal to the roof. The pedestalalso has a top wall surface with means for attaching the solar panel.The top wall surface may be partially or entirely defined by theattaching means.

A method for mounting a solar panel above a roof includes the steps ofapplying a foam adhesive to the roof and positioning a pedestal havingkeyways onto the foam adhesive. A solar panel is then positioned overand secured to the top wall surface of the pedestal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an improved roof ridge system madeaccording to this invention. A longitudinally extending rigid memberhaving keyways along at its top and bottom wall is received by acontinuous strip paddy of foam adhesive that has been applied to a roofunderlayment. A trim tile is then received by a paddy of foam adhesivethat has been applied to the top wall of the rigid member.

FIG. 2 illustrates the step of applying the foam adhesive to the roofunderlayment located at a ridge or field roof portion of a roof prior topositioning the rigid member of FIG. 1.

FIG. 3 illustrates the step of positioning the rigid member of FIG. 1and placing or embedding the keyways of the bottom wall into the foamadhesive.

FIG. 4 illustrates the step of applying a continuous strip paddy of foamadhesive to the top wall of the rigid member of FIG. 3.

FIG. 5 illustrates the steps of applying optional weather block to thefield tiles located on both sides of the positioned rigid member of FIG.4 and positioning a trim tile over the top wall of the member. A paddyof foam adhesive is also preferably applied to the underside of the trimtile.

FIG. 6 is an isometric view of an improved apparatus for mounting asolar panel above a roof according to this invention. A pedestal havingkeyways along its bottom wall surface is received by a paddy of foamadhesive that has been applied to the roof. A solar panel is thenattached to the pedestal by means on the top wall surface of thepedestal.

FIG. 7 illustrates the step of applying the foam adhesive to the roofprior to positioning the pedestal of FIG. 6.

FIG. 8 illustrates the step of positioning the pedestal of FIG. 6 andplacing or embedding the keyways of the bottom wall surface into thefoam adhesive.

FIG. 9 is an isometric view of the pedestal of FIG. 6 after it has beenset into place by the foam adhesive.

FIG. 10 is an isometric view of the pedestal of FIG. 6 showing the solarpanel attached to the top wall surface of the pedestal.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of an improved ridge tile system for a roof willnow be described by making reference to the drawings and the followingelements illustrated in the drawings:

10 Ridge tile system 20 Rigid member 21 Top wall 22 End of 21 23 Bottomwall 24 End of 23 25 Side wall 26 End of 25 31 Compartment or passageway33 Protrusion 34 Wall surfaces of 33 35 Keyway 37 Groove or track 51Field tile 53 Trim tile 55 Underlayment 57 Decking 60 Foam adhesive 70Weather block

Referring to the drawings and first to FIG. 1, a ridge tile system 10includes a longitudinally extending rigid member 20 having a top wall21, a bottom wall 23, and side walls 25. Side walls 25 provide thedesired height to rigid member 20 and may be arranged perpendicular towalls 21, 23. Alternatively, the walls 25 may be arranged in some otherorientation including but not limited to a cross-, web-, triangle-, orcircle-shaped design. The ends 26 of walls 25 may be offset relative tothe ends 22, 24 of walls 21, 23 or set flush with ends 22, 24. Rigidmember 20 is preferably a 2 inch×4 inch rigid member but can be made indifferent width and height combinations.

Preferably, rigid member 20 is extruded in 10-foot lengths using anolefin-based polymer and has a central passageway 31 extending along itslength. (Shorter or longer lengths may be extruded.) Central passageway31 allows rigid member 20 to house wiring, cabling or other roofingproducts (not shown) or to receive an insulating or other type ofmaterial. Central passageway 31 may be divided into two or morepassageways. The passageway 31 may also be partially filled orcompletely eliminated, with side walls 25 forming a solid side wall 25.

Top and bottom walls 21, 23 include one or more protrusions 33 extendingaway from the respective wall 21, 23. Each protrusion 33 includes akeyway 35. The keyways 35 are designed to receive a foam adhesive 60 andprovide additional surface area for bonding with adhesive 60. POLYPRO®AH-160 Roof Tile Adhesive (Polyfoam Products, Inc., Tomball, Tex.) is asuitable adhesive for use as adhesive 60. In a preferred embodiment,each keyway 35 is formed by the opposing inner wall surfaces 34 of eachprotrusion 33. Alternatively, two adjacent protrusions 33 could bespaced and arranged relative to one another so as to effectively form akeyway 35 having a desired shape between the two protrusions 33.

In a preferred embodiment, top and bottom walls 21, 23 include fourequally spaced protrusions 31 having keyways 35 and forming threegrooves or tracks 37. Each of the two middle protrusions 31 is asymmetrical U-shaped protrusion having a slotted keyway 35. Each of thetwo outer protrusions is asymmetrical Y-shaped protrusions having awedge-shaped keyway 35. A portion of these outer protrusions 31 extendbeyond the end 22, 24 of its respective top or bottom wall 21, 23respectively. Each protrusion 31 and keyway 35 is analogous to an armand receiver combination.

Using the keyways 35 on bottom wall 23 as an example—and referring alsoto FIGS. 2 & 3—a continuous strip paddy of uncured adhesive 60 isapplied to the roof underlayment 55 located at a ridge or field tileportion of a roof prior. Rigid member 20 is then placed on or pressedinto the adhesive 60. The adhesive 60 expands into the keyways 35 ofbottom wall 23, surrounds the protrusions 33 of the wall 23, and enterstracks 35 formed by adjacent protrusions 33. As adhesive 60 finishesexpanding and cures, adhesive 60 mechanically bonds with the keyways 35,protrusions 33, and tracks 37 and locks rigid member 20 into place. Theheight of the protrusions 33 provides the desired, minimum amountspacing between the wall 23 and the underlayment 55. The protrusions 33therefore help ensure that an adequate amount of adhesive 60 residesbetween the wall 23 and the underlayment 55 for proper bonding of one tothe other. As a result of the above, rigid member 20 is firmly securedto the roof underlayment 55. No penetration of the underlayment 55 ordecking 57 takes place (see FIG. 1).

Referring now to FIGS. 1, 4 & 5, a continuous paddy of adhesive 60 isapplied to top wall 21 of the positioned rigid member 20. Adhesive 60expands into the keyways 35, surrounds the protrusions 33 and enterstracks 35 of top wall 21. A continuous paddy of optional weather block70 is then laid down on the field tiles 53 located on opposing sides ofpositioned rigid member 20. Trim tiles 53 are then positioned over thetop wall 21, each trim tile 53 being received by the adhesive 60 and theweather block 70 (if used). Field and trim tiles 51, 53 are of a typewell known in the art. A paddy of adhesive 60 may also be applied to theunderside of each trim tile 53 prior to its placement onto positionedrigid member 20. Adhesive 60 cures and mechanically bonds and locks inthe trim tiles 53 to the top wall 21. As with the bottom wall 23, theheight of the protrusions 33 on the top wall 21 provides the desiredamount of spacing between the wall 21 and the trim tile 53 and helpsensure that enough adhesive 60 resides between the wall 21 and the trimtile 53 for proper bonding of one to the other.

Preferred embodiments of a system for mounting solar panels above a roofwill now be described by making reference to the drawings and thefollowing elements illustrated in the drawings:

 75 System  80 Pedestal  81 Top wall  83 Bottom wall  85 Side wall  90Protrusion  95 Keyway  97 Flat surface or plate of attaching means  99Receiver of attaching means 100 Solar panel

Referring to FIG. 6, a system 75 for mounting a solar panel above a roofincludes a pedestal 80 having a top wall 81, a bottom wall 83, and sidewalls 85. Side walls 85 provide the desired height for the pedestal 80and may be arranged perpendicular to the top and bottom walls 81, 83.The pedestal 80 may be configured as a rectangle, square, or othershape. The dimensions of pedestal 80 may vary depending upon thecharacteristics of the solar panel (or other object being mounted topedestal 80) and the surface to which the solar panel (or object) is tobe mounted or secured.

The surface of the bottom wall 83 of the pedestal 80 includes one ormore protrusions 90 extending away from the bottom wall 83. Eachprotrusion 90 includes a keyway 95 within it, which is designed toreceive a foam adhesive 60 and provide additional surface area forbonding with adhesive 60. In a preferred embodiment, each keyway 95 isformed by the opposing inner wall surfaces of each protrusion 90.Alternatively, two adjacent protrusions 90 could be spaced and arrangedrelative to one another so as to effectively form a keyway 95 having adesired shape between the two protrusions 90. The surface of the topwall 81 of the pedestal 80 may have a similar series of protrusions 90and keyways 95. The surface of the top wall 81 also includes means formounting and securing a solar panel to the pedestal 80. Such means mayinclude a flat surface or plate 97 and a receiver 99 such as eye-boltsor supports extending away from the flat surface which receive a portionof the solar panel and through which fasteners can be passed. The topwall 81 may be defined in part (or entirely by) the flat surface orplate 97. In other words, the top wall 81 does not include protrusions90 or keyways 95.

Referring to FIGS. 7 through 9, a paddy of uncured foam adhesive 60 isapplied to the roof at the location where the pedestal 80 is to bepositioned. The pedestal 80 is then placed on and pressed into theadhesive 60. The adhesive 60 expands into the keyways 95 and surroundsthe protrusions 90 along the surface of the bottom wall 83 of thepedestal 80. As the adhesive 60 finishes expanding and cures, itmechanically bonds with the keyways 95 and protrusions 90, securelylocking the pedestal 80 into place. The height of the protrusions 90 andthe pedestal 80 provide the desired minimum amount of spacing betweenthe roof and the solar panel. The protrusions 90 also help ensure thatthe amount of adhesive 60 used is adequate to properly bond the pedestal80 to the roof. Finally, as shown in FIG. 10, the solar panel 100 ispositioned over the pedestal 80 and attached to the surface of the topwall 81 of the pedestal 80. Different types, numbers, and configurationsof pedestals may be used depending upon the specific characteristics ofthe solar panel installation at a given site.

While a ridge tile or solar panel attachment system and method for itsuse have been described with a certain degree of particularity, manychanges may be made in the details of construction and the arrangementof components without departing from the spirit and scope of thisdisclosure. A system and method according to this disclosure, therefore,is limited only by the scope of the attached claims, including the fullrange of equivalency to which each element thereof is entitled.

What is claimed is:
 1. An apparatus for mounting or securing a piece ofroof-mounted equipment above a roof, the apparatus comprising: apedestal having a top wall surface and a bottom wall surface spacedapart from one another by a side wall surface; a plurality ofprotrusions extending along and away from a portion of said bottom wallsurface; one or more protrusions including a keyway, said keyway capableof receiving an adhesive for securing said pedestal to a roof; and meanson said top wall surface for attaching a piece of roof-mounted equipmentto said pedestal.
 2. An apparatus according to claim 1 furthercomprising said protrusions providing space between said bottom wallsurface and the roof so that an adhesive for bonding said pedestal tothe roof resides between said bottom wall surface and the roof.
 3. Anapparatus according to claim 1 wherein said keyway lies between opposingwall surfaces of one protrusion in said plurality of protrusions.
 4. Anapparatus according to claim 1 wherein said attaching means forms aportion of said top wall surface.
 5. An apparatus according to claim 1wherein the pedestal is secured to the roof without means forpenetrating a roof decking.
 6. An apparatus according to claim 1 whereinthe pedestal is a plastic member.
 7. An apparatus according to claim 1wherein the roof-mounted equipment is a solar panel.
 8. An apparatusaccording to claim 1 wherein the top wall surface is a top wall of thepedestal and the bottom wall surface is a bottom wall of the pedestal.9. An apparatus according to claim 1 wherein the keyway is located at anupper end of the protrusion.
 10. An apparatus according to claim 1wherein the attaching means is a plurality of protrusions extendingalong and away from a portion of said top wall surface, one or moreprotrusions including a keyway capable of receiving an adhesive.
 11. Anapparatus according to claim 10 wherein said keyway lies betweenopposing wall surfaces of one protrusion in said plurality ofprotrusions.
 12. An apparatus according to claim 10 wherein the keywayis located at an upper end of one protrusion in said plurality ofprotrusions.